H2-rich syngas production from gasification involving kinetic modeling: RSM-utility optimization and techno-economic analysis

In this research article, H2 rich syngas production is optimized using response surface methodology (RSM) and a utility concept involving chemical kinetic modeling considering eucalyptus wood sawdust (CH1.63O1.02) as gasification feedstock. By adding water gas shift reaction, the modified kinetic model is validated with lab scale experimental data (2.56 <= root mean square error <= 3.67). Four operating parameters (i.e., particle size dp, temperature T, steam to biomass ratio SBR, and equivalence ratio ER) of air-steam gasifier at three levels are used to frame the test cases. Single objective functions like H2 maximization and CO2 minimization are considered whereas for multi-objective function a utility parameter (80% H2 : 20% CO2) is considered. The regression coefficients (RH22 = 0.89, RCO22 = 0.98 and RU2 = 0.90) obtained during the analysis of variance (ANOVA) confirm a close fitting of the quadratic model with the chemical kinetic model. ANOVA results indicate ER as the most influential parameter followed by T, SBR, and dp. RSM optimization gives H2|max = 51.75 vol%, CO2|min = 14.65 vol% and utility gives H2|opt. = 51.69 vol% (0.11%down arrow), CO2|opt. = 14.70 vol% (0.34%up arrow). The techno-economic analysis for a 200 m3 per day syngas production plant (at industrial scale) assured a payback period of 4.8 (similar to 5) years with a minimum profit margin of 142% when syngas selling price is set as 43 INR (0.52 USD) per kg.

Automated summary

This research article focuses on the optimization of H2 rich syngas production using response surface methodology (RSM) and chemical kinetic modeling. Eucalyptus wood sawdust is used as the gasification feedstock. The study validates a modified kinetic model with lab scale experimental data and considers four operating parameters to frame the test cases. The results show that RSM optimization can achieve a high H2 content of 51.75 vol% and a low CO2 content of 14.65 vol%, while the utility concept provides a practical optimal solution with a slightly lower H2 content and slightly higher CO2 content. The techno-economic analysis demonstrates a payback period of 4.8 (similar to 5) years and a minimum profit margin of 142% for a 200 m3 per day syngas production plant.